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Pump Assembly Instructions For Z-Series Truck Pumps
1. Place the pump head on a clean work surface with the
bolting flange down.
2. Press the inner grease seal in through the main bearing
cavity until flush with the bottom of the bore. Seal lips must
be oriented down as shown in each parts detail drawing.
3. Press the main bearing into the head and install the
retainer ring.
4. Install the relief fitting into 1/8" NPT threaded hole and
turn the head over.
5. After lubricating the mechanical seal seat with light oil,
press the seal seat into the head using your fingers.
Make sure the seal seat is fully seated and the shiny
side faces up. Apply a generous amount of light oil to
the seal seat to remove any remaining debris and
fingerprints. Install the case O-ring around the pilot OD
of the head.
6. Press the outer grease seals into each of the
bearing caps.
7. Press the spring pins into each of the cam key holes.
8. Install the cam key into the pump case. Slide the cam
into the pump case aligning the long inlet slots to the
inlet portion of the case.
9. Install one sideplate and bolt one head into place with
two bolts.
10. Turn the pump onto the assembled head. Ensure there
is enough room to allow the shaft to extend through
the assembled head by 6 inches.
11. While holding the rotor-shaft vertical, install the vane
drivers. Vertically install the rotor-shaft into the unit.
Slide the vanes into each rotor slot ensuring the
rounded tip contacts the cam and the vane slots face
into the direction of rotation as shown in each parts
detail drawing.
12. Install the remaining sideplate.
13. Lubricate the pump shaft and seal carbon with light oil.
Install the seal retainer assembly by aligning the retainer
slot onto the seal alignment pin. Carefully press the seal
carbon into the retainer assembly with the polished face
oriented outward by aligning the carbon notches to the
retainer pins. Again, apply a generous amount of light
oil to remove any remaining debris and fingerprints.
14. Carefully install the head over the pump shaft and seal
assembly and torque the bolts in accordance with the
appropriate bolt torque pattern drawing. This pattern
ensures even bolting of the head into the case without
deforming the cam inlet port. This is done by bolting
those bolts over the solid portion of the cam port.
15. Turn the pump over and remove the first head.
16. Install the seal retainer assembly and carbon as
outlined in step 13 above.
17. Bolt head to case as described in step 14 above. Ensure
the rotor shaft turns freely in either direction.
18. Slide the bearing race mounting ring onto one end of
the shaft until contact with the main bearing inner race.
Mount the thrust bearing assembly onto the bearing
race mounting ring and install the bearing cap.
19. Lightly tighten the bearing cap with two opposed bolts
until the rotor shaft cannot be freely turned. Measure
the gap between the head and bearing cap at four
points around the bearing cap. Adjustment may be
necessary to contain the gap within .001". Round up
the average measurement to the nearest even number.
This is the measured amount of bearing cap shims.
Refer to parts pages for shim measurements.
20. Remove the two bearing cap bolts and install the
measured amount of shims plus .006". Install the four
bearing cap bolts and torque in a crossing pattern.
21. Install the remaining bearing race mounting ring
and thrust bearing assembly on the opposite side
of the pump.
22. Perform step 19 again on the opposite side and install
the measured shims plus .002". Install the four bearing
cap bolts and torque in a crossing pattern.
23. Install the shaft key and ensure shaft rotates smoothly.
12
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